H-4071-8504-02-A

Installation guide H-4071-8504-02-A

OMP40-2 optical machine probe

? 2007 Renishaw plc. All rights reserved. This document may not be copied or reproduced in whole or in

part, or transferred to any other media or language, by any means, without the prior written permission of Renishaw. The publication of material within this document does not imply freedom from the patent rights of Renishaw plc.

Renishaw part no: H-4071-8504-02-A Issued: 07.2007

Contents

Section 1

Before you get startedProvides information on patents, trademarks, declarations of conformity, warranty and safety.

Section 2

OMP40-2 basicsAn overview of the OMP40-2.

Section 3

System installationExplanation of how to install the batteries within the probe module, how to mount the OMP40-2 on a shank and how to align the stylus with the machine spindle. Information is also provided on how to site each of Renishaw's receiver units within the machine to obtain the optimum optical performance.

Section 4

Trigger Logic?The 'Trigger Logic?' method developed by Renishaw, allows probe settings to be configured using a sequence of stylus deflections.

Section 5

Service and maintenanceKeeping your OMP40-2 in good working order.

Section 6

TroubleshootingFind the solution.

Section 7

Parts listFind the part you require from our comprehensive list of spare parts and accessories.

OMP40-2 installation guide

Contents (continued)

Section 8

Probe settings recordKnow your probe settings at a glance.

Section 9

Definition of probing termsKnow what is meant by the terms commonly associated with probing.

Before you get startedDisclaimer Considerable effort has been made to ensure that the contents of this document are free from inaccuracies and omissions. However, Renishaw makes no warranties with respect to the contents of this document and specifically disclaims any implied warranties. Renishaw reserves the right to make changes to this document and to the product described herein without obligation to notify any person of such changes. Trademarks RENISHAW? and the probe emblem used in the RENISHAW logo are registered trademarks of Renishaw plc in the UK and other countries. apply innovation and Trigger Logic are trademarks of Renishaw plc. All other brand names and product names used in this document are trade names, service marks, trademarks, or registered trademarks of their respective owners. Warranty Equipment requiring attention under warranty must be returned to your equipment supplier. No claims will be considered where Renishaw equipment has been misused, or where repairs or adjustments have been attempted by unauthorised persons. Changes to equipment Renishaw reserves the right to change equipment specifications without notice. CNC machines CNC machine tools must always be operated by fully trained personnel in accordance with the manufacturer's instructions. Care of the probe Keep system components clean and treat the probe as a precision tool. Patents Features of the OMP40-2 probe, and other similar Renishaw probes, are subject of one or more of the following patents and/or patent applications:EP 0337669 EP 0390342 EP 0695926 EP 0974208 EP 1130557 EP 1185838 EP 1373995 EP 1397637 EP 1425550 EP 1477767 EP 1477768 EP 1503524 B EP 1701234 EP 1734426 JP 2,945,709 JP JP JP JP JP JP 2,994,401 2003-526,170 2004-522,961 2004-530,234 2005-502,035 2006-313567

1.2

US 5,040,931 US 5,150,529 US 5,669,151 US 6,776,344 B2 US 6,839,563 B1 US 6,860,026 B2 US 6,941,671 B2 US 6472981 B2 US 7145468 B2

FCC Section 15.19 This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: 1. This device may not cause harmful interference. 2. This device may accept any interference received, including interference that may cause undesired operation. FCC Section 15.105

1.3

has been manufactured in conformity with the following standards: BS EN 61326:1998/ A1:1998/A2:2001 Electrical equipment for measurement, control and laboratory use EMC requirements. Immunity to annex A industrial locations. Emissions to class A (non-domestic) limits. EN 60825-1:1993/ A1:1997/A2:2001 Safety of laser products. Part 1: Equipment classification, requirements and user’s guide.

and that it complies with the requirements of directives (as amended): 89/336/EEC Electromagnetic compatibility (EMC) Low voltage

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference, in which case you will be required to correct the interference at your own expense. FCC Section 15.21 The user is cautioned that any changes or modifications not expressly approved by Renishaw plc, or authorised representative could void the user’s authority to operate the equipment. Warning labels to be placed on equipment and for information to be supplied to the user.

73/23/EEC

The above information is summarised from the full EC Declaration of Conformity. A copy is available from Renishaw on request.

Before you get started

C

FCC DECLARATION (USA)

OMP40-2 installation guide

Before you get started

SafetyInformation for the user Handle and dispose of batteries in accordance with the manufacturer's recommendations. Use only the recommended batteries. Do not allow the battery terminals to contact other metallic objects. Information for the machine supplier/ installer ? It is the machine supplier's responsibility to ensure that the user is made aware of any hazards involved in operation, including those mentioned in Renishaw product literature, and to ensure that adequate guards and safety interlocks are provided. Under certain circumstances, the probe signal may falsely indicate a probe seated condition. Do not rely on probe signals to halt the movement of the machine. Information for the equipment installer All Renishaw equipment is designed to comply with the relevant EEC and FCC regulatory requirements. It is the responsibility of the equipment installer to ensure that the following guidelines are adhered to, in order for the product to function in accordance with these regulations: ? any interface MUST be installed in a position away from any potential sources of electrical noise, i.e. power transformers, servo drives etc; all 0V / ground connections should be connected to the machine 'star point' (the 'star point' is a single point return for all equipment ground and screen cables). This is very important and failure to adhere to this can cause a potential difference between grounds; all screens must be connected as outlined in the user's instructions; cables must not be routed alongside high current sources, i.e. motor power supply cables etc, or be near high speed data lines; cable lengths should always be kept to a minimum;

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1.4

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CAUTION: The OMP40-2 has a glass window, handle with care if broken to avoid injury.

IntroductionWelcome to the OMP40-2 job set-up and inspection probe, an upgrade of the multiple award winning OMP40. At only 40 mm diameter this compact probe sets industry standards for functionality, reliability and robustness in the harshest of machine tool environments. The OMP40-2 is ideal for small to medium machining centres including the growing range of HSK machines. Legacy or modulated transmission modes Modulated transmission is a method of sending signals from the probe to the interface to reduce the effects of light interference that in certain circumstances could cause false triggers in earlier legacy systems. Modulated transmission is capable of providing two different coded start signals. This allows the use of two probes with one interface. Twin probe installations require an OMI-2T interface. Twin probe system To operate a twin probe system, one probe needs to be set to probe 1 start and the other set to probe 2 start, these settings are user configurable. In a twin probe system such as a spindle probe and an optical tool setting probe, the spindle probe would be set to probe 1 start and the tool setter would be set to probe 2 start. Trigger Logic? The user can configure probe settings quickly and easily by deflecting the stylus in a sequence until the correct colour configuration is observed on the LED display, this programmable method is known as Trigger Logic?.OMP40-2 basics

Modes of operation NOTE: A visual indication of currently selected probe settings is provided, on battery insertion, by the three multicolour LEDs located within the probe window (see Section 4 - Trigger Logic?).

The OMP40-2 has three modes: Standby mode: where the probe is awaiting a switch-on signal: Operational mode: where the probe has been activated: Configuration mode: where Trigger Logic? may be used to configure the probe settings.

Probe settings continuedOMP40-2 basics

Switch-on/switch-off methods

Enhanced trigger filter Probes subjected to high levels of vibration or shock loads may output signals without having contacted any surface. The enhanced trigger filter improves the probes resistance to these effects. When the filter is enabled, a constant 10 ms delay is introduced to the probe output. This is factory set to trigger filter off. NOTE: It may be necessary to reduce the probe approach speed to allow for the increased stylus overtravel during the extended time delay.

Switch-on method Optical on Optical switch-on when commanded by an M code.

Switch-off methods available Optical off Optical switch-off when commanded by an M code. Note: This option is required when operating a twin probe system with OMI-2T. Note: A timer automatically switches the probe off after 90 minutes from the last trigger if not turned off by an M code.

2.3

Optical on Optical switch-on when commanded by an M code, or when commanded by an auto start.

Timer off (time out) Timer off 1 12 seconds Timer off 2 33 seconds Timer off 3 134 seconds Note: Time out is factory set to 134 seconds and will occur after the last probe trigger or reseat. Note: Ensure that the probe does not remain active in the tool changer when optical on/time out option is selected by observing the LEDs.

OMP40-2 installation guide

Probe settings continuedOMP40-2 basics

Optical transmission method The OMP40-2 can be operated in either legacy or modulated mode. The modulated mode has a higher resistance to light interference. Certain forms of light interference can cause false triggers or mimic a start signal and falsely activate the probe. These effects are much reduced when modulated transmission is selected. Legacy mode When set to legacy mode, the probe will only function with an OMI or OMM/MI 12. If start problems are experienced in legacy mode, activate the Legacy Start Filter ON option. This introduces a 1 second delay to the probe switch on time, and improves the probes resistance to false starts caused by light interference. NOTE: The probing program on the machine will need to take account of this delay.

Low optical power Where the separation between the OMP40-2 and the receiver is small (no more than 2 metres), the low optical power setting may be selected. This setting will reduce the optical transmission range and extend battery life. Factory setting is standard power.

2.4

Modulated mode When set to modulated mode, the probe will only function with an OMI-2, OMI-2T OMI-2H or OMI-2C interface. For most applications the spindle probe should be set to probe 1 start. Probe 2 start should only be selected for a secondary spindle probe in a twin probe application.

1/2 AA Lithium Thionyl Chloride (3.6 V) x 2 Approximately 1 week after a low battery warning is first given Blue flashing LED in conjunction with normal red or green probe status LED Constant or flashing red

ContentsPreparing the OMP40-2 for use ...................................................... 3.2 Fitting the stylus................................................................................. 3.2 Installing the batteries ....................................................................... 3.3 Mounting the probe on a shank ......................................................... 3.4 Stylus on-centre adjustment .............................................................. 3.5 Mounting the probe on the optional shank adaptor ........................... 3.6 Installing the OMP40-2 with an OMI-2T/OMI-2/OMI-2H or OMI ............................................ 3.8 Performance envelope when using the OMP40-2 with an OMI-2T/OMI-2/OMI-2H (modulated transmission) ................ 3.9 Performance envelope when using the OMP40-2 with an OMI (legacy transmission) .................................................... 3.9 Installing the OMP40-2 with an OMM and MI 12 interface ................................................. 3.10 Performance envelope when using the OMP40-2 with an OMM (modulated transmission) .......................................... 3.11 Calibrating the OMP40-2 ............................................................... 3.12 Probe datuming - general ................................................................ 3.12 Probe datuming - OMP40-2 ............................................................ 3.12

OMP40-2 installation guide

Preparing the OMP40-2 for useSystem installation

Fitting the stylus

3.2

M-5000-3707

Installing the batteries

3.3

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CAUTION If dead batteries are inadvertently inserted into the probe then the LEDs will remain a constant red. Do not allow coolant or debris to enter the battery compartment. When inserting batteries, check that the battery polarity is correct.

All Renishaw equipment is designed to comply with the relevant EEC and FCC regulatory requirements. It is the responsibility of the equipment installer to ensure that the following guidelines are adhered to, in order for the product to function in accordance with these regulations: ? any interface MUST be installed in a position away from any potential sources of electrical noise, i.e. power transformers, servo drives etc; all 0V / ground connections should be connected to the machine 'star point' (the 'star point' is a single point return for all equipment ground and screen cables). This is very important and failure to adhere to this can cause a potential difference between grounds; all screens must be connected as outlined in the relevant user instructions; cables must not be routed alongside high current sources, i.e. motor power supply cables etc, or be near high speed data lines;

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cable lengths should always be kept to a minimum.

The probe and receiver must be in the other's field of view, and within the performance envelope shown. The OMP40-2 performance envelope is based on the receiver being at 0°, and vice-versa. Natural reflective surfaces within the machine may change the signal transmission range. Coolant residue accumulating on the probe or receiver windows will have a detrimental effect on transmission performance. Wipe clean as often as is necessary to maintain unrestricted transmission. Operation in temperatures of 0 °C to 5 °C or 50 °C to 60 °C (32 °F to 41 °F or 122 °F to 140 °F) will result in some reduction in range.

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CAUTION: If two systems are operating in close proximity to each other, take care to ensure that signals transmitted from the probe on one machine are not received by the receiver on the other machine, and vice versa. When this is the case, use the probe’s low power mode and/or receiver low range setting.

All Renishaw equipment is designed to comply with the relevant EEC and FCC regulatory requirements. It is the responsibility of the equipment installer to ensure that the following guidelines are adhered to, in order for the product to function in accordance with these regulations: ? any interface MUST be installed in a position away from any potential sources of electrical noise, i.e. power transformers, servo drives etc; all 0V / ground connections should be connected to the machine 'star point' (the 'star point' is a single point return for all equipment ground and screen cables). This is very important and failure to adhere to this can cause a potential difference between grounds. all screens must be connected as outlined in the relevant user instructions; cables must not be routed alongside high current sources, i.e. motor power supply cables etc, or be near high speed data lines; cable lengths should always be kept to a minimum.

The probe and OMM diodes must be in the other's field of view, and within the performance envelope shown. The OMP40-2 performance envelope is based on the OMM being at 0°, and vice-versa. Natural reflective surfaces within the machine may change the signal transmission range. Coolant residue accumulating on the OMP40-2 or OMM windows will have a detrimental effect on transmission performance. Wipe clean as often as is necessary to maintain unrestricted transmission. Operation in temperatures of 0 °C to 5 °C or 50 °C to 60 °C (32 °F to 41 °F or 122 °F to 140 °F) will result in some reduction in range. On large machine tools, it is possible to provide greater reception coverage by mounting two OMMs connected to a single MI 12 interface. CAUTION: If two systems are operating in close proximity to each other, take care to ensure that signals transmitted from the probe on one machine are not received by the receiver on the other machine, and vice versa. When this is the case, use the probe’s low power mode and/or receiver low range setting.

Probe datuming - general Often referred to as ‘calibration’ or ‘qualifying’, probe datuming involves the measurement of a calibrated feature, usually a precision ring gauge or reference sphere of precisely known diameter. Datuming software then compares the size of the ring gauge/sphere as ‘measured’ by the probe and machine tool to its calibrated size, thus calculating the ‘effective’ diameter of the stylus tip. As each spindle probe system is unique, it is imperative that you datum your probe: ? ? ? before it is used for the first time; when a new, replacement stylus is fitted; if it is suspected that the stylus has become distorted; periodically to allow for any thermal growth of the machine tool;

Probe datuming - OMP40-2 probe NOTE: Best accuracy will be achieved by minimising stylus on-centre errors during probe installation. This is necessary to allow for poor probe location in the spindle following a tool change, spindle orientation repeatability and ‘hunting’ of the spindle orientation if not mechanically clamped. Stylus ball centre to spindle centre-line relationship can be compensated for by suitable calibration of a known feature.

3.12

To relate the actual location of the workpiece surface to the machine tool’s reference frame, it is necessary to datum your OMP40-2 probe. This will allow you to: ? determine the position of the stylus ball centreline relative to the machine spindle centreline; determine the effective size of the stylus ball (electronic ball radius).

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? ? if the repeatability of relocation of the probe shank is poor (datuming may be required each time the probe is selected); whenever the probe is moved from one machine tool to another; whenever a new shank is fitted to the probe.

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Prior to datuming, you will need to establish the optimum length and diameter of the stylus to be used. To datum the probe:

Changing the current probe settingsInsert batteries or, if already installed, remove for 5 seconds and replace. Allow the probe to run through the review sequence until the 'optical power' setting is showing. Immediately deflect the stylus and hold deflected until five red flashes have been observed (if the battery power is low then each of the five red flashes will be until the 'switch off method' setting is displayed, then release the stylus. The probe is now in configuration mode and Trigger Logic? is activated.Trigger Logic?

followed by a blue flash). Keep the stylus deflected

Key to the symbols LED short flash. LED long flash. Deflect the stylus. Wait less than 4 seconds before moving to next menu option. Deflect the stylus. Wait more than 4 seconds before moving to next menu. To exit, leave the stylus untouched for more than 20 seconds. Battery status Battery good or Battery low

4.31 2 wait more than 5 seconds 3Deflect the stylus and hold deflected until the battery status has been displayed at the end of the review sequence.LED check

Constant red Flashing red or flashing red and green or sequence when batteries are inserted

Battery dead

Unsuitable battery

NOTE: Due to the nature of Lithium Thionyl Chloride batteries, if a 'low battery' LED sequence is ignored or overlooked, then it is possible for the following sequence of events to occur: 1. When the probe is active, the batteries discharge until battery power becomes too low for the probe to operate correctly. The probe stops functioning, but then re-activates as the batteries recharge sufficiently to provide the probe with power. The probe begins to run through the LED review sequence (see page 4.2). Again, the batteries discharge and the probe ceases to function. Again, the batteries recharge sufficiently to provide the probe with power and the sequence repeats itself.

Wipe window of probe with a clean cloth to remove machining residue. This should be done on a regular basis to maintain good optical transmission.

5.2

Changing the batteriesService and maintenance

5.3

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CAUTION Do not leave exhausted batteries in probe When changing batteries, do not allow coolant or debris to enter the battery compartment When changing batteries, check that the battery polarity is correct

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CAUTION Please dispose of exhausted batteries in accordance with local regulations Do not dispose of batteries in a fire

Check that OMP40-2 and receiver windows are clean, and remove any obstruction. Check alignment and if receiver fixing is secure Check start signal by reviewing receiver start LED. Refer to relevant user’s guide.

Probe out of range/not aligned with receiver. No receiver start signal.

Machine stops unexpectedly during a probing cycle.

Optical communication obstructed.

Check interface/receiver and remove obstruction. Refer to interface/receiver/machine user’s guide. Change batteries. Enable enhanced trigger filter. Check that part is correctly positioned and that stylus has not broken. Reconfigure adjacent probe to low power mode and reduce range of receiver. Check that the probe and receiver windows are clean, and remove any obstruction.

Kinematic switching probe A contact probe in which the kinematic seating forms an electrical circuit that is broken by the action of displacing the stylus, to provide the trigger signal. After displacement, the stylus ball returns to the highly repeatable position defined by the kinematic location points. Lobing The variation in trigger point position from a perfect spherical locus, as the direction of probing varies. Overtravel The distance travelled by the probe after the trigger point has been reached. Pre-travel The displacement from the point where the stylus ball contacts the workpiece, to the point where a probe trigger is asserted. Pre-travel variation The deviation of the pre-travel from its average value as it varies with trigger direction. This may be specified for 2D (X-Y) or 3D (X-Y-Z) measurements. Pre-travel itself is not a form of error, since it can easily be compensated for, by probe calibration. Strain gauge probe Although a strain gauge probe still uses a kinematic mechanism to retain the stylus, it does not use the resistance through the contact elements as the means to sense a trigger. Instead, a set of strain gauges are positioned on carefully designed webs within the probe structure, beyond the kinematics. These gauges measure the contact force applied to the stylus and generate a trigger. This provides a low trigger force, low pre-travel and therefore low pre-travel variation.

The closeness of agreement between the results of a measurement and the true value of the part being measured. Repeatability The variation in measurements obtained when multiple readings are taken with the same instrument and technique on the same part or item. In Renishaw terms, repeatability is the ability of a probe to trigger at the same point each time. Calibration The operation that identifies and corrects any deviation from the stated performance targets. Probe calibration Where a datum feature, of known size and position, is measured to establish the average pre-travel for the stylus concerned. Datum The reference feature from which other co-ordinates are measured. Hysteresis A systematic error arising from the difference in direction of a probing move resulting from the preceding reseat. Kinematic seating A seating mechanism in which the spatial position of a movable component is constrained in all 6 degrees of potential movement. This is achieved in a Renishaw probe by 6 contact points formed by a system of radial rollers (or ‘V’ grooves) and ball bearings.